Itelco Industry AQH 20 Manual

AQL/AQH 20-35
Air Cooled Water Chillers and Heat Pump
Refrigeratori d’Acqua e Pompe di Calore Raffreddati ad Aria
Refrigerateurs à Eau et Pompes de Chaleur Refroidies à Air
Luftgekühlte Wasserkühler und Wärmepumpen
Refrigeradores de Agua y Bombas de Calor Refrigerados por Aire
IOM AQ410-N.1 ALL
Part number / Codice / Code / Code / Código : 035B09040-000
Supersedes / Annulla e sostituisce / Annule et remplace / Annulliert und ersezt /
Anula y sustituye: None / Nulla / Néant / Nicht / Ninguno
“Notified Body /Organismo Notificato / Organisme Notifié / Benannte
Zertifizierungsstelle / Organismo Notificado No. 1115 ”
Installation and maintenance manual
Manuel d’installation et de maintenance
Installations- und Wartungshandbuch
Manuale di installazione e di manutenzione
Manual de instalación y de mantenimiento
English Français
20
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35 kW
20
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40 kW
EspañolDeutsch Italiano
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Page 1
Table of contents
English
1 FOREWORD
1.1 Introduction 3
1.2 Warranty 3
1.3 Emergency stop/Normal stop 3
1.4 An introduction to the manual 3
2 SAFETY
2.1 Foreword 4
2.2 Definitions 4
2.3 Access to the unit 5
2.4 General precautions 5
2.5 Precautions against residual risks 5
2.6 Precautions during maintenance
operations 6
2.7 Safety labels 7
2.8 Safety regulations 9
3 TRANSPORTATION, HANDLING
AND STORAGE
3.1 Inspection 12
3.2 Handling 12
3.3 Anchoring 13
3.4 Storage 13
4 INSTALLATION
4.1 Installation Site 14
4.2 External Water Circuit 14
4.3 Water connections 16
4.4 Defrost water drainage
(only for AQH units) 16
4.5 Water buffer tank 16
4.6 Power supply 17
4.7 Electrical Connections 18
5 START-UP
5.1 Preliminary Checks 20
5.2 Start-up 20
5.3 Checking the operation 21
5.4 Delivery to the customer 21
6 AQL/AQH CONTROL
6.1 Electronic Card Control 22
6.2 Dip Switches 23
6.3 ALAr and LOg Menu 26
6.4 SEnS Menu –Sensor reading 27
7 PRODUCT DESCRIPTION
7.1 General Information 28
7.2. Accessories 29
7.3 Refrigerant Circuits 32
8 TECHNICAL DATA
8.1 Hydraulic Features 34
8.2 Electrical Characteristics 37
8.3 Working Range 38
8.4 Dimensional Drawings 40
8.5 Space Requirements 41
9 MAINTENANCE
9.1 General requirements 42
9.2 Planned maintenance 42
9.3 Refrigerant charge 43
9.4 Compressor 43
9.5 Condenser 43
9.6 Fans 43
9.7 Dehydrating filter 43
9.8 Sight glass 43
9.9 Thermostatic expansion valve 44
9.10 Evaporator 44
9.11 Troubleshooting 45
Table of contents

Page 2
Table of contents
10 SPARE PARTS
10.1 Spare part list 47
10.2 Oils for compressors 47
10.3 Wiring diagrams 47
11 DISMANTLING, DEMOLITION
AND SCRAPPING
11.1 Generalities 48

Page 3
Foreword
English
1 FOREWORD
1.1 Introduction
Itelco-Industry units, manufactured to state-of-the-art
design and implementation standards, ensure top
performance, reliability and fitness to any type of air-
conditioning systems.
These units are designed for cooling water or glyco-
led water (and for water heating in heat pump mo-
dels) and are unfit for any purposes other than those
specified in this manual.
This manual includes all the information required for
a proper installation of the units, as well as the rele-
vant operating and maintenance instructions.
It is therefore recommended to read this manual ca-
refully before installation or any operation on the
machine. The chiller installation and maintenance
must be carried out by skilled personnel only (where
possible, by one of Itelco-Industry’s Authorised Servi-
ce Centers).
The manufacturer may not be held liable for any da-
mage to people or property caused by improper
installation, start-up and/or improper use of the unit
and/or failure to implement the procedures and in-
structions included in this manual.
1.2 Warranty
These units are delivered complete, tested and ready
for being operated. Any form of warranty will beco-
me null and void in the event that the appliance is
modified without Itelco-Industry’s preliminary written
authorisation.
This warranty shall apply providing that the instal-
lation instructions have been complied with (either
issued by Itelco-Industry, or deriving from the current
practice), and the Form 1 (“Start-up”) has been fil-
led-in and mailed to Itelco-Industry (attn. After-Sales
Service).
In order for this warranty to be valid, the following
conditions shall be met:
■The machine must be operated only by skilled per-
sonnel from Itelco-Industry’s Authorised After-Sales
Service.
■Maintenance must be performed only by skilled
personnel - from one of Itelco-Industry’s Authorised
After-Sales Centers.
■Use only original Itelco-Industry spare parts.
■Carry out all the planned maintenance provided
for by this manual in a timely and proper way.
Failure to comply with any of these conditions will
automatically void the warranty.
1.3 Emergency stop / Normal stop
The emergency stop of the unit can be enabled using
the master switch on the control panel (move down
the lever).
For a normal stop, press the relevant push-buttons.
To restart the appliance, follow the procedure detai-
led in this manual.
1.4 An introduction to the manual
For safety reasons, it is imperative to follow the in-
structions given in this manual. In case of any dama-
ge caused by non-compliance with these instructions,
the warranty will immediately become null and void.
Conventions used throughout the manual:
The Danger sign recalls your attention to a
certain procedure or practice which, if not
followed, may result in serious damage to
people and property.
The Warning sign precedes those proce-
dures that, if not followed, may result in se-
rious damage to the appliance.
The Notes contain important observations.
The Useful Tips provide valuable informa-
tion that optimises the efficiency of the ap-
pliance.
This manual and its contents, as well as the docu-
mentation which accompanies the unit, are and re-
main the property of Itelco-Industry, which reserves
any and all rights thereon. This manual may not be
copied, in whole or in part, without Itelco-Industry’s
written authorization.

Page 4
Safety
2 SAFETY
2.1 Foreword
These units must be installed in conformity with the
provisions of Machinery Directive 98/37/EC, Low
Voltage Directive 2006/95/EC, Pressure Vessels Di-
rective 97/23/EC, Electromagnetic Interference Di-
rective 89/336/EC, as well as with other regulations
applicable in the country of installation. If these pro-
visions are not complied with, the unit must not be
operated.
The unit must be grounded, and no instal-
lation and/or maintenance operations
may be carried out before deenergising the
electrical panel of the unit.
Failure to respect the safety measures mentioned
above may result in electrocution hazard and fire in
the presence of any short-circuits.
Inside the heat exchangers, the compressors
and the refrigeration lines, this unit contains
liquid and gaseous refrigerant under pres-
sure. The release of this refrigerant may be
dangerous and cause injuries.
The units are not designed to be operated
with natural refrigerants, such as hydrocar-
bons. Itelco-Industry may not be held liable
for any problems deriving from the replace-
ment of original refrigerant or the introduc-
tion of hydrocarbons.
Itelco-Industry units are designed and manufactured
according to the requirements of European Standard
PED 97/23/EC (pressure vessels).
– The used refrigerants are included in group II (non-
hazardous fluids).
– The maximum working pressure values are mentio-
ned on the unit’s data plate.
– Suitable safety devices (pressure switches and sa-
fety valves) have been provided, to prevent any
anomalous overpressure inside the plant.
– The vents of the safety valves are positioned and
oriented in such a way as to reduce the risk of con-
tact with the operator, in the event that the valve
is operated. Anyway, the installer will convey the
discharge of the valves far from the unit.
– Dedicated guards (removable panels with tools)
and danger signs indicate the presence of hot pi-
pes or components (high surface temperature).
The guards of the fans (only for units pro-
vided with air heat exchangers) must be
always mounted and must never be remo-
ved before de-energising the appliance.
It is the User’s responsibility to ensure that
the unit is fit for the conditions of intended
use and that both installation and main-
tenance are carried out by experienced
personnel, capable of respecting all the re-
commendations provided by this manual.
It is important that the unit is adequately
supported, as detailed in this manual. Non-
compliance with these recommendations
may create hazardous situations for the
personnel.
The unit must rest on a base which meets
the characteristics specified in this manual;
a base with inadequate characteristics is
likely to become a source of serious injury
to the personnel.
The unit has not been design to withstand
loads and/or stress that may be transmitted
by adjacent units, piping and/or structures.
Each external load or stress transmitted to
the unit may break or cause breakdowns in
the unit’s structure, as well as serious dan-
gers to people. In these cases, any form of
warranty will automatically become null
and void.
The packaging material must not be dispo-
sed of in the surrounding environment or
burnt.
2.2 Definitions
OWNER: means the legal representative of the com-
pany, body or individual who owns the plant where
Itelco-Industry unit has been installed; he/she has the
responsibility of making sure that all the safety regu-
lations specified in this manual are complied with,
along with the national laws in force.
INSTALLER: means the legal representative of the
company who has been given by the owner the job
of positioning and performing the hydraulic, electric
and other connections of Itelco-Industry unit to the
plant: he/she is responsible for handling and pro-
perly installing the appliance, as specified in this
manual and according to the national regulations in
force.

Page 5
Safety
English
OPERATOR: means a person authorised by the ow-
ner to do on Itelco-Industry unit all the regulation
and control operations expressly described in this
manual, that must be strictly complied with, without
exceeding the scope of the tasks entrusted to him.
ENGINEER: means a person authorised directly by
Itelco-Industry or, in all EC countries, excluding Italy,
under his full responsibility, by the distributor of Itel-
co-Industry product, to perform any routine and ex-
traordinary maintenance operations, as well as any
regulation, control, servicing operations and the re-
placement of pieces, as may be necessary during the
life of the unit.
2.3 Access to the unit
The unit must be placed in an area which can be
accessed also by OPERATORS and ENGINEERS;
otherwise the unit must be surrounded by a fence at
not less than 2 meters from the external surface of the
machine.
OPERATORS and ENGINEERS must enter the fen-
ced area only after wearing suitable clothing (safety
shoes, gloves, helmet etc.). The INSTALLER personnel
or any other visitor must always be accompanied by
an OPERATOR.
For no reason shall any unauthorised personnel be
left alone in contact with the unit.
2.4 General precautions
The OPERATOR must simply use the controls of the
unit; he must not open any panel, other than the one
providing access to the control module.
The INSTALLER must simply work on the connections
between plant and machine; he must not open any
panels of the machine and he must not enable any
control.
When you approach or work on the unit, follow the
precautions listed below:
■do not wear loose clothing or jewellery or any
other accessory tat may be caught in moving parts
■wear suitable personal protective equipment (glo-
ves, goggles etc.) when you have to work in the
presence of free flames (welding operations) or
with compressed air
■if the unit is placed in a closed room, wear ear pro-
tection devices
■cut off connecting pipes, drain them in order to
balance the pressure to the atmospheric value be-
fore disconnecting them, disassemble connections,
filters, joints or other line items
■do not use your hands to check for any pressure
drops
■use tools in a good state of repair; be sure to have
understood the instructions before using them
■be sure to have removed all tools, electrical cables
and any other objects before closing and starting
the unit again
2.5 Precautions against residual risks
Prevention of residual risks caused by the
control system
■be sure to have perfectly understood the operating
instructions before carrying out any operation on
the control panel
■when you have to work on the control panel, keep
always the operating instructions within reach
■start the unit only after you have checked its perfect
connection to the plant
■promptly inform the ENGINEER about any alarm
involving the unit
■do not reset manual restoration alarms unless you
have identified and removed their cause
Prevention of residual mechanical risks
■install the unit according to the instructions provi-
ded in this manual
■carry out all the periodical maintenance operations
prescribed by this manual
■wear a protective helmet before accessing the inte-
rior of the unit
■before opening any panelling of the machine,
make sure that it is secured to it by hinges
■do not touch air condensation coils without wea-
ring protective gloves
■do not remove the guards from moving elements
while the unit is running
■check the correct position of the moving elements’
guards before restarting the unit
Prevention of residual electrical risks
■connect the unit to the mains according to the in-
structions provided in this manual
■periodically carry out all the maintenance opera-
tions specified by this manual
■disconnect the unit from the mains by the external
disconnecting switch before opening the electrical
board
■check the proper grounding of the unit before start-
up
■check all the electrical connections, the connecting
cables, and in particular the insulation; replace
worn or damaged cables

Page 6
Safety
■periodically check the board’s internal wiring
■do not use cables having an inadequate section or
flying connections, even for limited periods of time
or in an emergency
Prevention of other residual risks
■make sure that the connections to the unit conform
to the instructions provided in this manual and on
the unit’s panelling
■if you have to disassemble a piece, make sure that
it has been properly mounted again before restar-
ting the unit
■do not touch the delivery pipes from the compres-
sor, the compressor and any other piping or com-
ponent inside the machine before wearing protec-
tive gloves
■keep a fire extinguisher fir for electrical appliances
near the machine
■on the units installed indoor, connect the safety
valve of the refrigeration circuit to a piping network
that can channel any overflowing refrigerant outsi-
de
■remove and leak of fluid inside and outside the unit
■collect the waste liquids and dry any oil spillage
■periodically clean the compressor compartment, to
remove any fouling
■do not store flammable liquids near the unit
■do not disperse the refrigerant and the lubricating
oil into the environment
■weld only empty pipes; do not approach flames or
other sources of heat to refrigerant pipes
■do not bend/hit pipes containing fluids under pres-
sure
2.6 Precautions during maintenance
operations
Maintenance operations can be carried out by au-
thorised technicians only.
Before performing any maintenance operations:
■disconnect the unit from the mains with the external
disconnecting switch
■place a warning sign “do not turn on - maintenance
in progress” on the external disconnecting switch
■make sure that on-off remote controls are inhibited
■wear suitable personal protective equipment (hel-
met, safety gloves, goggles and shoes etc.)
To carry out any measurements or checks which re-
quire the activation of the machine:
■work with the electrical board open only for the
necessary time
■close the electrical board as soon as the measure-
ment or check has been completed
■for outdoor units, do not carry out any operations
in the presence of dangerous climatic conditions
(rain, snow, mist etc.)
The following precautions must be always adopted:
■do not scatter the fluids of the refrigeration circuit in
the surrounding environment
■when replacing an eprom or electronic cards, use
always suitable devices (extractor, antistatic brace-
let, etc.)
■to replace a compressor, the evaporator, the con-
densing coils or any other weighty element, make
sure that the lifting equipment is consistent with the
weight to be lifted
■in air units with independent compressor compart-
ment, do not access the fan compartment unless
you have disconnected the machine by the discon-
necting switch on the board and you have placed
a warning sign “do not turn on - maintenance in
progress”
■contact Itelco-Industry for any modifications to the
refrigeration, hydraulic or wiring diagram of the
unit, as well as to its control logics
■contact Itelco-Industry if it is necessary to perform
very difficult disassembly and assembly operations
■use only original spare parts purchased directly
from Itelco-Industry or the official retailers of the
companies on the recommended spare parts list
■contact Itelco-Industry if it is necessary to handle
the unit one year after its positioning on site or if
you wish to dismantle it.

Page 7
English
Safety
2.7 Safety labels
The labels below will be affixed to each unit in the indicated point:
Identification of the unit
Outside, on the right-hand front column
Electrical warning
Adjacent to the master switch
Identification of the refrigerant
External door
Product code A
Model B
Notified body C
Serial number D
Year of construction E
Refrigerant type F
Refrigerant charge G
High pressure H
Low pressure I
Main supply L
Start up current M
Full load current N
Power input O
Water operation pressure P
Mass Q
IP class R
Use of filter and flow switch
Adjacent to fittings

Page 8
Safety
Grounding connection - On the electrical
board, adjacent to the connection
Final Test Certificate -
Inside the external door
Lifting point - Base
Start-up warning - Outside the door of the
electrical board
Fitting identification -
Adjacent to fittings

Page 9
English
Safety
2.8 Safety regulations
Refrigerant data
Toxicity Low
Contact with skin If sprayed, the refrigerant is likely to cause frost burns. If absorbed by
the skin, the danger is very limited; it may cause a slight irritation, and
the liquid is degreasing. Unfreeze the affected skin with water. Remove
the contaminated clothes with great care - in the presence of frost burns,
the clothes may stick to the skin. Wash with plenty of warm water the
affected skin.
In the presence of symptoms such as irritation or blisters, obtain medi-
cal attention.
Contact with eyes
Ingestion
Inhalation
Recommendations
Prolonged exposure
Vapours do not cause harmful effects. The spraying of refrigerant may
cause frost burns. Wash immediately with a proper solution or with tap
water for at least 10 minutes, and then obtain medical attention.
Very unlikely - should something happen, it will cause frost burns.
Do not induce vomiting. Only if the patient is conscious, wash out mou-
th with water and give some 250 ml of water to drink. Then, obtain
medical attention.
R410A: remarkable concentrations in the air may have an anaesthetic
effect, up to fainting. The exposure to considerable amounts may cause
irregular heartbeat, up to the sudden death of the patient. Very high
concentrations may result in the risk of asphyxia, due to the reduction in
the oxygen percentage in the atmosphere. Remove the patient to fresh
air and keep warm and at rest.
If necessary, give oxygen. In case of breathing difficulties or arrest, pro-
ceed with artificial respiration. In case of cardiac arrest, proceed with
cardiac massage. Then, obtain medical attention.
Semiotics or support therapy is recommended. Cardiac sensitisation
has been observed that, in the presence of circulating catecholamines
such as adrenalin, may cause cardiac arrhythmia and accordingly, in
case of exposure to high concentrations, cardiac arrest.
R410A: a study on the effects of exposure to 50,000 ppm during the
whole life of rats has identified the development of benign testicle tu-
mour. This situation should therefore be negligible for personnel expo-
sed to concentrations equal to or lower than professional levels.
Professional levels
Stability R410A: Not specified
R410A: Recommended threshold: 1000 ppm v/v - 8 hours TWA.
Conditions to avoid Do not use in the presence of flames, burning surfaces and excess humi-
dity.
Safety data: R410A
Hazardous reactions May react with sodium, potassium, barium and other alkaline metals.
Incompatible substances: magnesium and alloys with magnesium con-
centrations > 2%.
Hazardous decomposition
products R410A: Halogen acids produced by thermal decomposition and hydrolysis.

Page 10
Safety
Respiratory system protection
Storage
Protective clothing
Accidental release measures
Disposal
Fire fighting information
Cylinders
Protective fire fighting
equipment
If you are in doubt about the concentration in the atmosphere, it is re-
commended to wear a respirator approved by an accident-prevention
Authority, of the independent or oxygen type.
Cylinders must be stored in a dry and fresh place, free from any fire
hazard, far from direct sunlight or other sources of heat, radiators etc.
Keep a temperature below 50°C.
Wear overalls, protective gloves and goggles or a mask.
It is important to wear protective clothing and a respirator. Stop the
source of the leak, if you can do this without danger. Negligible leaks
can be left evaporating under the sun, providing that the room is well
ventilated. Considerable leaks: ventilate the room. Reduce the leak with
sand, earth or other absorbing substances. Make sure that the liquid
does is not channelled into gutters, sewers or pits where the vapours
are likely to create a stuffy atmosphere.
The best method is recovery and recycling. If this method is not practi-
cable, dispose according to an approved procedure, that shall ensure
the absorption and neutralization of acids and toxic agents.
R410A: Not flammable in the atmosphere.
In case of fire, wear an independent respirator and protective clothing.
The cylinders, if exposed to fire, shall be cooled by water jets; othe-
rwise, if heated, they may explode.
General precautions Do not inhale concentrated vapours. Their concentration in the atmo-
sphere should not exceed the minimum preset values and should be
maintained below the professional threshold. Being more weighty than
the air, the vapour concentrates on the bottom, in narrow areas. There-
fore, the exhaust system must work at low level.

Page 11
English
Safety
Lubricant oil data
Classification Not harmful
Contact with skin
Contact with eyes
Ingestion
Inhalation
Conditions to avoid
Protection of the respiratory
system
Protective clothing
Accidental release measures
Disposal
Fire fighting information
Cylinders
Fire fighting protective
equipment
May cause slight irritation. Does not require first aid measures. It is
recommended to follow usual personal hygiene measures, including
washing the exposed skin with soap and water several times a day. It is
also recommended to wash your overalls at least once a week.
Wash thoroughly with a suitable solution or tap water.
Seek medical advice immediately.
Seek medical advice immediately.
Strong oxidising substances, caustic or acid solutions, excess heat.
May corrode some types of paint or rubber.
Use in well ventilated rooms.
Always wear protective goggles or a mask. Wearing protective gloves
is not mandatory, but is recommended in case of prolonged exposure
to refrigerant oil.
It is important to wear protective clothing and, especially, goggles.
Stop the source of the leak. Reduce the leak with absorbing substances
(sand, sawdust or any other absorbing material available on the
market).
The refrigerant oil and its waste will be disposed of in an approved
incinerator, in conformity with the provisions and the local regulations
applicable to oil waste.
In the presence of hot liquid or flames, use dry powder, carbon dioxide
or foam. If the leak is not burning, use a water jet to remove any va-
pours and to protect the personnel responsible for stopping the leak.
The cylinders exposed to a fire will be cooled with water jets in case of
fire.
In case of fire, wear an independent respirator.
Safety data: Polyester oil (POE)

Page 12
Transportortion, Handling and Stockage
3 TRANSPORTATION, HANDLING
AND STORAGE
AQL/AQH units are supplied fully assembled and
tested (except for accessories supplied loose in the
units – absorbers, filter, etc.). They are ready to be
installed and started on the field.
R410A units are only charged with liquid refrigerant
and with oil in the quantity required for operation.
The low pressure side of the refrigerating
circuit on R410A units shall be charged by
means of the service valve arranged on the
thermal expansion valve before the device
is operated.
3.1 Inspection
The unit shall be immediately inspected upon receipt
to find out any damage since it has been delivered
ex works and transported at the customer’s risk. It is
also necessary to make sure that all the parcels spe-
cified on the delivery note have been delivered.
Any damage you may find out shall be immediately
reported in writing to the carrier. Even if the damage
is only on the surface, please notify our local repre-
sentative too.
The manufacturer disclaims all responsibility for the
shipment even if it has provided for its organisation.
3.2 Handling
AQL/AQH units are designed to be lifted from abo-
ve, by means of cables and eyebolts. A spacer shall
be arranged between the cables in order to prevent
them from damaging the unit (see the figure aside).
Before handling the devices, make sure the site you
have chosen for the installation can withstand its wei-
ght and support its mechanical impact.
Avoid touching sharp parts (such as the fins of batte-
ries, for example) while handling the unit.
The unit shall never be placed on rollers.
Act as follows to lift and handle the unit:
■ Insert and secure the eyebolts into the frame holes
which have been marked on purpose.
■ Connect the cables to the eyebolts.
■ Insert the spacer between the cables.
■ Provide for hooking at the centre of gravity of the
device.
■ Cables shall have such a length that the angle they
form with the horizon when under tension is not
less than 45°.
While lifting and handling the unit, pay
attention. Otherwise, you might damage
the finned pack of the batteries arranged
on both sides of the unit. The sides of the
unit shall be protected by cardboard or
plywood sheets.
Until the unit is ready for operation, do not
remove the plastic envelope and the battery
protections which are intended to prevent
dirt, dust and any foreign matter from pene-
trating into the unit through the inlets of fans
or from damaging the external surfaces.
Space requirements
request to handling
Holes Ø 30 mm

Page 13
English
3.3 Anchoring
It is not essential to secure the unit to the foundations,
unless in areas where there is a serious risk of earth-
quake, or if the appliance is installed on the top of a
steel frame.
3.4 Storage
If the unit is to be stored before the installation for
some time, take at least the following precautions to
prevent damage, corrosion and/or deterioration:
■ Make sure all openings, such as for example wa-
ter connections, are well plugged and sealed.
■ Never store the units in a room where temperature
is above 50 °C (R410A units) or where the units
are directly exposed to the sunlight.
■ Minimum storage temperature is -25 °C.
■ It is recommended to leave the finned batteries co-
vered to protect them against any risk of corrosion,
especially if building works are still in progress.
■ Store the units in areas where minimum activity is
likely to take place in order to avoid any risk of
accidental damage.
■ Never use steam to clean the unit.
■ Remove all the keys required to have access to the
control panel and give them to the person in char-
ge of the field.
It is also recommended to provide for visual inspec-
tions at regular intervals.
Transportortion, Handling and Stockage

Page 14
Installation
4 INSTALLATION
4.1 Installation Site
Before installing the unit, make
sure that the building structure
and/or the supporting surface can
withstand the weight of the device.
The weights of the units are de-
tailed by Chapter 8 of this manual.
These units have been designed to be installed on
the floor, in the open air. As a standard, they are
equipped with rubber vibration-damping supports
which shall be arranged in the middle, beneath the
supporting plates.
When the unit is to be installed on the ground, pro-
vide for a concrete bedplate which shall assure a
uniform distribution of the weights. No special sub-
base is generally required.
When selecting the installation site, never forget to
consider as follows:
■The longitudinal axis of the unit shall be parallel
to the direction of the prevailing winds so as
to assure a uniform air distribution on finned
exchangers.
■The unit shall never be installed in the proximity of
chimneys for the discharge of boiler flue gases.
■The unit shall never be installed downwind of
sources of grease contaminated air, such as for
example the outlets of large-kitchen extractors.
Otherwise, grease might build up on the fins of
refrigerant / air exchangers or condensers, act
as a fixing agent for any sort of atmospheric im-
purity and rapidly cause the exchangers to clog.
■The unit shall never be installed in areas exposed
to heavy snowfalls.
■The unit shall never be installed in areas exposed
to flooding or beneath drip stones, etc.
■The unit shall never be installed in narrow inner
court yards or in any other restricted space where
the noise may be reflected by the walls or where
the air expelled by the fans may short-circuit on
the refrigerant/air heat exchangers or condensers.
■The installation site shall be characterised by the
presence of the space required for air circulation
and for the performance of maintenance opera-
tions (see chapter 8 for further details).
4.2 External Water Circuit
The external water circuit shall guarantee
a constant water flow rate through the cir-
culating refrigerant/water heat exchanger
(evaporator) under steady operating condi-
tions and in case of a load variation.
The circuit shall be composed by the following ele-
ments:
■A circulation pump which can ensure the neces-
sary flow rate and head.
■The total content of the primary water circuit shall
never be lower than 2.5 lt/kW in terms of refri-
gerating capacity. If the total water volume in the
primary circuit should be unable to reach such a
value, an additional heat-insulated storage tank
should be installed. This tank is intended to avoid
any repetitive start of the compressor.
■A membrane expansion tank complete with a sa-
fety valve and a drain which shall be visible.
The expansion tank shall be dimensioned
in such a way that it can absorb a 2%
expansion of the total volume of the wa-
ter in the plant (exchanger, pipelines,
uses and storage tank, if available). The
expansion tank shall never be insulated
when the circulating fluid is not flowing
through it.
A differential pressure switch is mounted as a stand-
ard. It will stop the unit whenever it senses a load
loss through the heat exchanger which may result in
a flow rate problem.
In addition:
■Install on/off valves (accessory) on the lines at the
inlet and outlet of the manifolds of the exchangers
(evaporator).
■Arrange a by-pass complete with an on/off valve
between the manifolds of the heat exchangers.
■Arrange air vent valves at the high points of the
water lines.
■Arrange drain points complete with plugs, clocks, etc.
in the proximity of the low points of the water lines.
■Insulate the water lines to prevent the heat from
blowing back into the unit.

Page 15
English
Installation
Components:
1. 2. 3. 4. 5. 6. 7. 8. 9.
10. 11. 12. 13.
Plate heat exchange Pump Drain valve Water buffer tank Water filter Automatic water charging valve Pressure expansion tank Water chargin line Water outlet Water inlet Globe valve Flexible pipes By pass valve
Safety/control devices:
A.
B.
C.
D.
E.
F.
FS.
G.
I.
Inlet water temperature sensor Outlet water temperature sensor
Water differential pressure switch Vent valve Water safety valve Manometer Flow switch Thermometer Hydrometer
(105 mBAR)
(3 BAR)
— - - — Unit Side
- - - - - - - Optional parts
Probes connection Water drain Pressure connection Standard connection

Page 16
Installation
Before filling the installation, remove any
impurity, such as sand, crushed stones and
welding scales, coating drops and any
other material which might damage the
evaporator.
It is advisable to flush with disposable water by-
passing the exchanger to avoid clogging.
The water used to fill the circuit shall be
treated in such as way that the pH will
have the correct value.
When two or several units are connected in paral-
lel, to balance the load losses of the various circuits,
it is recommended to execute a “reverse return”
connection (see the diagram below).
4.3 Water connections
The attachments at the water inlet and out-
let shall be connected in compliance with
the instructions which can be found on the
labels in the proximity of the attachments.
Connect the water lines of the plants with the attach-
ments of the unit whose diameters and positions are
shown by Chapter 8.
4.4 Defrost water drainage
(only for AQH units)
When heat pump units work in heating mode, dur-
ing defrosting cycles, they may discharge water
from the base. This is why the units should be in-
stalled at least 200 mm above the floor level, so as
to allow the free drainage of waste water, without
the risk of producing ice banks.
The heat pump units must be installed in positions
where the defrosting water cannot create any dam-
age.
4.5 Water buffer tank
The accumulation tank which has been designed to
be mounted on AQL/AQH units is complete with all
the hydraulic and electrical components required
for the correct operation of the system.
These systems are carefully assembled and tested
at works. They are ready for operation after having
correctly realised all electrical and hydraulic con-
nections.
4.5.1 Features
Units have one single tank. The kit will include an
Antifreeze Electric Heater, a drain valve, an auto-
matic filling unit and an automatic air vent.
No pump is arranged on the kit since it is mounted
on the unit.
A tank arranged for mounting a heating booster re-
sistance kit may be optionally required (5 traps).
The tank is completely insulated with 30 Kg/m3
closed cell polyethylene in a silver colour and en-
closed by a bearing structure made of passivated
and painted plates. The box is equipped with bulk-
heads which can be easily opened for internal
inspection.
The kit is installed beneath the chiller. It is an inte-
gral part of the unit without changing the support
area.
4.5.2 Supplied Material
The kits will be supplied with pipelines ready for
installation. An antifreeze resistance with wiring, an
automatic water filling valve, a 3 bar safety valve,
a drain valve and a vent valve have already been
assembled.
Hydrokit is shipped with a film to protect it from at-
mospheric agents. Packaging has been designed in
order to stack it up.
4.5.3 Operating Limits
The unit will guarantee the operation down to
–10°C air temperature with fan speed control in
cooling mode with one single antifreeze resistance,
while in standard configuration (without fan spped
control) down to 10°C ambient temperature.
Maximum operating temperature is 50 °C. Maximum
installation altitude is 1.000 [m] sea level. Maximum
relative humidity is 87 % in heating mode.
4.5.4 Shock Absorbers
Shock absorbers are supplied as a standard.
UNIT 1
UNIT 2
Legend
S On/Off valves
VG Balancing valves

Page 17
English
Installation
4.5.5 Antifreeze Electric Heater
The antifreeze resistance of the tank (TEH) shall be
wired with the panel as it is shown by the diagram
attached to the unit.
4.5.6 Water Filter
The kit will use the water filter of the unit.
CAUTIONS
The unit + tank system shall be equipped with a fil-
ter. Use the filter + union as it is shown by Figure 1.
4.5.7 Installation Procedure
Hydrokit shall be arranged beneath the unit. It will
not change its overall dimensions (Figure 1).
Arrange the rubber shock absorbers beneath the kit
before providing for its connection.
Provide for the hydraulic and electrical connec-
tions. Doing that, observe the diameters shown
by the quoted drawings.
The wiring for the standard antifreeze resistance
is arranged as it is shown by . The resistance is
connected with the main terminal box.
See the wiring diagram attached to the unit for
the correct execution of the electrical connec-
tions.
Install the water filter as it is shown by Figure 1.
4.6 Power supply
Before carrying out any operations on the
electrical system, make sure that the unit is
deenergized.
It is important that the appliance is groun-
ded.
The company in charge of the installation
shall conform to the standards applicable to
outdoor electrical connections.
Itelco-Industry may not be held liable for any dama-
ge and/or injury caused by failure to comply with
these precautions.
The unit conforms to EN 60204-1.
The following connections shall be provided:
■A 3-phase and grounding connection for the
power supply circuit.
■The electrical distribution system shall meet the
power absorbed by the appliance.
■The disconnecting and magnetothermal switches
must be sized to control the starting current of the
unit.
■The power supply lines and the insulation devices
must be designed in such a way that every line in-
dependent.
■It is recommended to install differential switches,
to prevent any damage caused by phase drops.
■The fans and compressors are supplied through
contactors controlled from the control panel.
■Each motor is provided with an internal safety ther-
mal device and external fuses.
Positioning rubber
shock absorbers
Water filter
position
Figure 1

Page 18
Installation
Figure 1
Antifreeze
Resistance Wiring
Storage Kit (112 l) for AQL/AQH 20-35 - Dimensional Data
SIDE VIEW FRONT VIEW
TOP VIEW
NOTES:
A - WATER INLET ON THE PLANT SIDE Ø 1 1/2” GAS M
B - WATER OUTLET ON THE CHILLER SIDE Ø 1 1/2” GAS M
C - WATER FILLING Ø 1/2” GAS M
■The power supply cables must be inserted into de-
dicated openings on the front of the unit, and the
will enter the electrical board through holes drilled
on the bottom of the board.
4.7 Electrical connections
The unit must be installed on site according to the
usual procedures and standards applicable in the
place of installation. The unit must not be operated if
its installation has not been carried out according to
the instructions provided in this manual.
The power supply lines must consist of insulated cop-
per conductors, dimensioned for the maximum ab-
sorbed current.
Connection to terminals must be performed accor-
ding to the diagram of connections (User’s Terminal
Box) provided in this manual and according to the
wiring diagram which accompanies the unit.